Yamaha Road Star Repair Manual 1999-2005

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Item # M282  ISBN: 9780892879403




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This repair and service manual covers Yamaha Road Star from 1999 through 2005. Models covered in this manual are:

• XV1600A, XV1700A RoadStar 1999-2005
• XV1600AT, XV1700AT Road Star Silverado 1999-2005
• XV1600AS Road Star MM Limited 2000
• XV1600AS Road Star Midnight Star 2001-2003
• XV1600ALE Road Star Limited Edition 2003
• XV1600ATLE Road Star Silverado Limited Edition 2003
• XV1700AM Road Star Midnight 2004-2005
• XV1700ATM RoadStar Midnight Silverado 2004-2005

Note: this manual does not cover XV1700P Warrior models.

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION
Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING
Engine operating requirements | Starting the engine | Engine will not start | Engine performance | Engine noises | Engine lubrication | Engine leakdown test | Clutch | Gearshift linkage | Transmission | Carburetor | Carburetor heater | Fuel pump | Electrical testing | Electrical troubleshooting | Suspension and steering | Brake system

CHAPTER THREE: LUBRICATION, MAINTENANCE AND TUNE-UP
Fuel type | Maintenance intervals | Cylinder numbering | Engine rotation | Tune-up | Spark plugs | Engine oil | Transfer gearcase | Fuel and exhaust systems | Control cable lubrication | Clutch cable adjustment | Transmission | Sidestand | General lubrication | Battery | Tires | Front suspension | Steering head | Rear suspension | Drive belt | Brakes | Specifications

CHAPTER FOUR: ENGINE TOP END
Servicing engine in the frame | Cylinder head covers | Rocker arms and pushrods | Valve lifters | Cylinder head | Valves and valve components | Cylinder | Pistons and piston rings | Specifications

CHAPTER FIVE: ENGINE LOWER END
Engine | Oil filter mount | Camshafts | Oil pump | Crankcase | Crankcase seal and bearing replacement | Crankshaft | Connecting rods | Alternator drive shaft | Engine break-in | Specifications

CHAPTER SIX: TRANSFER GEARCASE
Drive sprocket | Transfer gearcase | Oil pump | Case and cover | Specifications

CHAPTER SEVEN: CLUTCH AND PRIMARY DRIVE GEAR
Clutch cover | Clutch | Primary drive gear | Oil pump driven gear | Specifications

CHAPTER EIGHT: TRANSMISSION AND SHIFT MECHANISM
Shift pedal | footrest assembly | External shift mechanism | Internal shift mechanism | Transmission | Specifications

CHAPTER NINE: FUEL, EXHAUST, AND EMISSION CONTROL SYSTEMS
Fuel system safety | Fuel hose identification | Fuel tank | Air filter housing | Surge tank solenoid valve (California models) | Carburetor | Carburetor overhaul | Pilot screw | Fuel level | Idle speed adjustment | Throttle cable adjustment | Throttle position sensor | Carburetor heater | Throttle cable replacement | Starter (choke) cable replacement | Fuel filters | Fuel pump | Fuel pump | fuel filter module | Air induction system | Evaporative emission control (California models) | Exhaust system | Specifications

CHAPTER TEN: ELECTRICAL SYSTEM
Electrical component replacement | Electrical connectors | Charging system | Alternator stator | Flywheel, starter clutch and starter reduction gears | Voltage regulator | rectifier | Ignition system | Spark plug cap | Ignition coil | Pickup coil and timing rotor | Diode (1999-2003) | Ignitor unit | Starting system | Starter | Starting circuit cutoff relay (Relay unit) | Starter relay | Lighting system | Headlight | Meter assembly | Taillight | brake light | License plate light | Signal system | Horn | Turn signals | Neutral indicator light | Speed sensor | Fuel level sender | Decompression solenoid | Switches | Self-diagnostic system | Fuses | Specifications

CHAPTER ELEVEN: WHEELS AND TIRES
Motorcycle stand | Brake rotor protection | Wheel inspection | Wheel bearings | Front wheel | Front hub | Rear wheel | Rear hub | Driven sprocket clutch hub | Drive belt | Laced wheel service | Wheel balance | Tire changing | Specifications

CHAPTER TWELVE: FRONT SUSPENSIONAND STEERING
Front fork | Handlebar | Steering head | Steering head bearing races | Lower bearing replacement | Specifications

CHAPTER THIRTEEN: REAR SUSPENSION
Shock absorber and suspension linkage | Swing arm | Specifications

CHAPTER FOURTEEN: BRAKES
Brake service | Preventing brake fluid damage | Brake bleeding | Brake fluid draining | Brake pads | Front caliper | Front master cylinder | Rear brake caliper | Rear brake master cylinder | Brake pedal | footrest assembly | Brake disc | Brake hose replacement | Specifications

CHAPTER FIFTEEN: BODY AND FRAME
Seats | Side covers | Rider footrest | Passenger footpegs | Front fender | Rear fender | Saddlebags and mounting brackets | Backrest | Sidestand | Windshield | Battery box | Specifications

COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

Yamaha Road Star Repair Manual 1999-2005